Optical Ground Wire (OPGW) Cable

Corporate Office: Apar House, Corporate Park, Sion Trombay Road, Chembur, Mumbai-400071. INDIA. Contact : (+91) (22) 25263400, 67800400 │Email : corporate@apar.com

Registered Office: 301, Panorama Complex, R.C.Dutt Road, Vadodara-390007. INDIA. Contact : (+91) (265) 2322798 │Email : apar.baroda@apar.com

OPGW is one of the most reliable fiber optic medium for the telecom service providers, ISPs, Cable TVs, or other organizations who are involved in the transmission of one or more form of voice, data, video, text, messages, conferencing and telemetering kind of things. Installation became widespread in the year 1980.In 2000, around 60,000km OPGW was installed worldwide.

Many electric utilities are installing high capacity fiber optic cables and wires on their high voltage lines to satisfy their own internal communication needs and to gain additional revenues by leasing excess capacity to telecommunication network providers.

Overhead transmission power line corridors provide the telecommunications industry with cost-effective alternative routes and at the same time benefit the electric utilities by generating additional revenues using existing facilities. The inherent advantage of fiber optic technology as a means of communication is that fiber optics provides fixed link, point to point communications with a remarkably high capacity for carrying data.

APAR has developed technical expertise in fiber optic cables and proven its capabilities in manufacture of energy efficient bare overhead power conductors. APAR has integrated these core strengths in its comprehensive OPGW solution that includes Optical Fiber Composite Ground Wire and related hardware.

Apar’s OPGW & OFC are approved by BSNL, CACT, PGCIL and other Power and Telecom Utilities.

ADVANTAGES OF OPGW CABLES Fiber optic communication cables are neither subject to electromagnetic

interference nor do they cause any interference.

Aerial fiber optic cables and any related equipment can be electrically insulatedfrom system components.

The technology offers very long information transmission distances of up to 80km (50 miles) without requiring the use of repeaters.

Fiber optic technology offers extremely high transmission capacity which can result in data transfer of information at rates of up to 3 gigabytes per second (Gbps)

OVERHEAD OPTICAL FIBER CABLE SYSTEMS

An Optical fiber is composed of a light guiding core surrounded by cladding. Both the core and the cladding are typically made of high purity glass typically derived from doped germanium or pure silica. The core and the cladding are then surrounded by one or two protective coatings of Acrylate that improves the strength characteristics of the Optical fibers.

Two main types of Optical fiber exist : a) single mode; b) multi-mode. In a single mode Optical fiber, the fiber core is small enough that only one mode of light can travel through the core at any one time. In a multi-mode fiber, the fiber core is large enough that multiple modes of light can travel through the core at different paths and lengths. It should be noted that the attenuation of the signal in single mode is significantly lower than in multi-mode fibers.

When combined with a method of construction suitable to the high strength, high voltage environment of utility corridors, aerial fiber optic cables and wires provide superior performance and reliability in communication networks.

CHARACTERSTICS OF OPTICAL FIBRES Particulars Unit G 652

(DWSM-A,B,C,D) G 655

(Non-zero dispersion shifted

fibers) Cladding diameter µm 125 ± 1 125 ± 0.7 Cladding non-circularity % ≤ 1.0 ≤ 0.7 Mode field diameter at 1310 nm µm 9.2± 0.4 - at 1550 nm µm 10.4 ± 0.8 9.6 ± 0.4 Attenuation at 1310 nm dB/km ≤ 0.35 at 1550 nm dB/km ≤ 0.20 ≤ 0.22 at 1625 nm dB/km - ≤ 0.24 Chromatic dispersion from 1285 to 1330 nm ps/ (nm.km) ≤ 3.5 at 1550 nm ps/ (nm.km) ≤ 18 2.80 to 6.20 at 1460 nm Ps/(nm.km) - -4.20 to 3.29 at 1625 nm 5.77 to 11.26 PMD (Polarization Mode Dispersion) ps/√km < 0.2 ≤ 0.2

Cable cut -off Wavelength nm ≤ 1260 ≤ 1450

OPTICAL FIBRE

OPGW CABLE WITH CENTRAL CORE ALUMINUM SHEATHED TUBE

OPGW cable with central core aluminum sheathed tube is made of polymer loose tubes and the outer layer can be a suitable combination of ACS and AA wires for the right ratings as required by the end-user.

SINGLE LAYER CONSTRUCTION

In composite conductors a fiber cable unit containing the Optical fibers is either integrated or embedded into a conductor or ground wire. In voltages below 138-kV the composite conductor can also be a phase wire. However, usually the fiber unit containing the Optical fibers is placed inside the ground wire. OPGW can be a light weight ground wire designed to be used as a static wire replacement or it can be installed in addition to conventional ground wire. Currently, the number of Optical fibers that can be readily fitted into an OPGW aerial wire construction can reach up to 144 fibers. The metallic wires have to give the OPGW aerial cable enough conductivity to carry fault currents, and the strength to withstand mechanical stresses.

DOUBLE LAYER CONSTRUCTION

The APAR-OPGW DOUBLE LAYER cables are used when the requirements are for a high ultimate load and/or high short-circuit current. Hydrogen-absorbent optical core is constructed with required number of optical fibers covered with tubes with loose fiber protection and sealed with moisture-proof gel and whole setup is protected with thermal protection tape to absorb the increased temperature. With choice of aluminum clad steel, aluminum alloy, galvanized steel wires Hydrogen-absorbent optical core is protected with extruded aluminum tube and surrounded with first layer with choice of aluminum clad steel, aluminum alloy, galvanized steel wires. Further surrounded with second layer with choice of aluminum clad steel, aluminum alloy, galvanized steel wires for additional high ultimate load and/or high short-circuit current.

PRODUCT RANGE

OPGW CABLE WITH STAINLESS STEEL TUBE AND ALUMINUM CLAD STEEL TUBE

OPGW cable with stainless Steel and aluminum clad

steel tube is available in fiber counts up to 48. The

cable can be designed into single or dual layered

construction in accordance to the mechanical and

electrical requirements as per application needs of

the end-user.

Due to its unique small size this becomes the perfect

solution for overloaded towers with its small diameter

and light weight construction. The fibers are

protected from environmental conditions to ensure

reliability and long life.

HIGH STRENGTH OPGW CABLE

High strength OPGW cable is available up to 96 fibers making it suitable for application is high

fiber count and super-high-voltage power lines. Steel tubes are stranded with Hi-strain steel

wires to create a dual-layer design suitable for a range of high strength applications. The layer

of Aluminum gives this product a high fault rating current values.

PRODUCT RANGE

TYPICAL DESIGNS OF SINGLE LAYER CONSTRUCTION CABLE:

Product Range Fiber count (Max )

Diameter ( mm)

Weight (kg/Km)

UTS ( KN)

Short Circuit (KA² Sec )

OPGW 12[55,20] 12 10.0 349 55 20

OPGW 12[64,35] 12 11.6 412 64 35

OPGW 16[91,58] 16 12.8 580 91 58

OPGW 24[53,23] 24 10.3 347 53 23

OPGW 24[74,26] 24 10.9 416 74 26

OPGW 24[63,30] 24 11.2 386 63 30

OPGW 24[78,37] 24 11.6 498 79 38

OPGW 24[65,40] 24 11.9 409 65 40

OPGW 24[81,41] 24 12.0 500 81 41

OPGW 24[77,43] 24 12.5 467 77 43

OPGW 24[64,68] 24 13.2 475 64 68

OPGW 24[100,40] 24 13.5 572 100 40

OPGW 24[62,91] 24 14.0 490 62 91

OPGW 24[65,116] 24 14.6 523 65 116

OPGW 24[97,110] 24 15.0 670 97 110

OPGW 36[79,36] 36 11.8 484 79 36

OPGW 36[72,67] 36 12.7 503 72 67

OPGW 48[41,29] 48 11.0 316 41 29

OPGW 48[74,35] 48 11.7 471 74 35

OPGW 48[63,44] 48 12.4 429 63 44

OPGW 48[59,77] 48 13.3 450 59 77

OPGW 48[99,83] 48 13.7 610 90 83

OPGW 48[89,151] 48 16.0 696 89 151

OPGW 64[98,76] 64 15.1 650 98 76

OPGW 96[103,138] 96 16.2 719 103 138

OPGW 288[82,198] 288 20.8 789 82 198

NOTE: The designs above are only a sampling of the options available from APAR. Please contact us for a cable designed to your exact specifications.

PRODUCT DESCRIPTION

TYPICAL DESIGNS OF DOUBLE LAYER CONSTRUCTION CABLE:

Product Range Fiber count (Max )

Diameter ( mm)

Weight (kg/Km)

UTS ( KN)

Short Circuit (KA² Sec )

OPGW 12[82,111] 12 15.3 600 82 111

OPGW 24[93,151] 24 15.9 645 93 151

OPGW 24[74,175] 24 16.6 585 74 175

OPGW 24[118,400] 24 19.0 860 118 400

OPGW 24[101,247] 24 17.7 744 101 247

OPGW 24[141,479] 24 20.7 1030 141 479

OPGW 32[102,237] 32 19.4 812 102 237

OPGW 36[188,212] 36 18.7 1161 188 212

OPGW 36[305,386] 36 22.0 1716 305 386

OPGW 48[92,122] 48 15.6 642 92 122

OPGW 48[88,278] 48 18.6 729 88 278

OPGW 48[147,201] 48 21.1 1065 147 501

OPGW 48[121,348] 48 19.4 892 121 348

OPGW 60[135,441] 60 20.6 999 135 441

OPGW 72[166,675] 72 22.9 1246 166 675

OPGW 96[158,826] 96 24.0 1277 158 826

OPGW 144[120,430] 144 22.4 1000 120 430

NOTE: The designs above are only a sampling of the options available from APAR. Please contact us for a cable designed to your exact specifications.

PRODUCT DESCRIPTION

TYPE TESTING All types of OPGW cable are type tested and validated from internationally acknowledged independent test laboratory according to IEC 60794 and IEEE 1138 Standards.

ROUTINE TESTING FACTORY ACCEPTANCE TESTING • Optical fiber attenuation coefficient• Inspection of Wires before stranding• Quality of Surface• Direction of Outer layer• Diameter of Cable• Weight of Cable• Packing Inspection

• Design Verification• Optical fiber attenuation coefficient• Mode Field Diameter of optical fiber• Cladding Diameter of optical fiber• Cladding non circularity of optical fiber• Visual inspection of the cable

elements• Lay length of Outer layer• Diameter of cable• Weight of cable• Breaking Strength of cable.

INHOUSE OPGW TEST FACILITIES

FIBER GEOMETRY SPLICER

MFD SPECTRAL ANALYZER + MFD

QUALITY & TESTING

QUALITY & TESTING

OTDR MICROSCOPE

SHEAVE TEST TENSILE TESTING MACHINE

VIBRATION TEST REPEATED BEND TEST

In order to ensure that the OPGW cables will operate successfully in a high voltage network, all aspects associated with the implementation of this technology must be correctly analyzed.

Maintenance, providing the material required (instruments, repair units, etc.) Optimized design of cables. Project support (calculation of spans, drum lengths, etc.) Definition of optical fiber Supervision of installation, to ensure correct cable stringing and splicing Test certificates (measurement of fiber attenuation)

APAR has designed global pre-sales and after-sales services to optimize the installation, operation and maintenance of these networks.

QUALITY & TESTING

TORSION TEST CRUSH TEST

GALLOPING TEST IMPACT TEST

OPGW Cables can be supplied in Wooden, Steel and Hybrid drums (Steel frame & HDPE plastic). Both ends of cable shall be securely fastened to drum and sealed with a shrinkable sleeve. The required marking shall be printed with a laminated paper on the outsides of drum according to customer’s requirement.

Typical Drum Dimensions:

Cable Diameter

Standard length of

Conductor (m)

Tolerance on

Standard length (%)

Drum Dimensions Volume in m3

Flange “A” Barrel “B” Traverse “C” (mm) (mm) (mm) (mm)

10.0 3000 ± 2% 1120 550 600 0.591 5000 ± 2% 1270 550 600 0.760 6000 ± 2% 1220 550 915 1.069

11.0 3000 ± 2% 1220 550 600 0.701 5000 ± 2% 1370 550 600 0.884 6000 ± 2% 1320 550 915 1.252

12.0 3000 ± 2% 1220 600 915 1.069 5000 ± 2% 1320 600 915 1.252 6000 ± 2% 1425 600 915 1.459

13.0 3000 ± 2% 1220 600 915 1.069 5000 ± 2% 1400 600 915 1.408 6000 ± 2% 1500 600 915 1.616

14.0 3000 ± 2% 1320 650 915 1.252 5000 ± 2% 1500 650 915 1.616

15.0 3000 ± 2% 1425 800 915 1.459 4000 ± 2% 1525 800 915 1.670

16.0 3000 ± 2% 1500 800 915 1.616 4000 ± 2% 1600 800 915 1.839

PACKAGING & DRUM

Cable Diameter

(mm)

Standard length of

Conductor (m)

Tolerance on

Standard length (%)

Drum Dimensions Volume in m3

Flange “A” Barrel “B” Traverse “C” (mm) (mm) (mm)

17.0 3000 ± 2% 1550 800 915 1.726

18.0 3000 ± 2% 1600 800 915 1.839

19.0 3000 ± 2% 1650 900 915 1.956

20.0 3000 ± 2% 1725 900 915 2.137

21.0 3000 ± 2% 1800 1000 915 2.327

22.0 3000 ± 2% 1850 1000 915 2.458

Photograph of Packed Drum for Reference

Steel Drums Hybrid Drums (Steel frame & HDPE plastic)

PACKAGING & DRUM

OPGW FITTINGS & HARDWARES

Joint Boxes EWMJ, up to 96 splices Joint Boxes EWJ, up to 240 splices Suspension assembly

Stockbridge Damper Spiral Vibration Damper

Downlead clamp Tension assembly

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